Disassembly

1. Remove both output shaft yoke nuts, washers and rubber seals. Remove rear output yoke and front output yoke from transfer case.

2. Disconnect speedometer pickup switch from rear bearing retainer.

3. Disconnect 4WD indicator switch from front case, then remove rear bearing retainer bolts from rear case.

4. Remove speedometer tone wheel from mainshaft using gear puller tool No. J-22912-01, or equivalent.

5. Remove output bearing snap ring from mainshaft using snap ring pliers tool No. J-8059, or equivalent.

6. Remove attaching screws from case halves. Screws are self-tapping; aluminum shavings are common when screws are removed.

7. Using a suitable tool, separate case halves.

8. Disconnect clutch coil wire connector and clutch coil attaching nuts from rear case half.






9. Disconnect spring from shift rail, then remove clutch coil housing snap ring and housing from mainshaft.






10. Remove synchronizer hub and assembly from mainshaft drive gear, then the mode shift fork from shift rail.

11. Remove front output shaft snap ring and washer from front output shaft.

12. Remove drive gear, driven gear and drive chain as an assembly.

13. Remove front output shaft from bearing.









14. Remove mainshaft and oil pump assembly from input carrier assembly.

15. Remove shift rail, range fork and shift hub from input carrier assembly.






16. Remove annulus gear snap ring and gear from front case.

17. Remove oil seal from mainshaft on front case.

18. Remove snap ring from carrier assembly input shaft.

19. Remove input carrier assembly and power take-off drive gear from front case.






20. Remove retaining clip, sector shaft, detent spring and roller from front case.

21. Remove front input snap ring and bearing, then the rear output bearing from rear case half, using bearing remover installer tool Nos. J-8092 and J-29169.

22. Remove front output shaft seal and bearing snap ring from front case.

23. Remove rear output shaft seal from rear bearing retainer.